WAFER Co Research Group

HYDROGEN PRODUCTION VIA CPV/SOEC ELECTROLYSIS INTEGRATED AS STAGE I REACTOR IN THE HABER-BOSCH AMMONIA SYNTHESIS
Kabolobari P. Benakole, B.Tech (Chemical Engineering) Principal Researcher, Wafer Co Research Group

March 2012

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Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

HYDROGEN PRODUCTION VIA CPV/SOEC ELECTROLYSIS INTEGRATED AS STAGE I REACTOR IN THE HABER-BOSCH AMMONIA SYNTHESIS Request for permission to propose a Study for Comparative Analysis of the Costs of CPV/SOEC Hydrogen Production System and Procurement of Hydrogen from Gas Companies Producing Hydrogen from Natural Gas/Hydrocarbons, for such a renewable system design incorporated into the overall reactor design for the synthesis of ammonia and electricity generation. To: Onajite Paul Okoloko, GMD/CEO, Notore Industries Femi Agbaje, CFO Charles Odita, CTO Ayo Balogun, CMO Femi Solebo, MD/CEO, Notore Power Bode Agagu, Head, Projects Delivery From: Kabolobari Precious Benakole, Chemical Engineer [B.Tech], Principal, Wafer Co Research Group (Incorporation pending) Date: April 2, 2012

1. Frame of Reference: The production of one metric ton (1 tonne) of ammonia (NH3) requires almost 2,000 m3 of hydrogen. Therefore, the ammonia synthesis (or fertilizer) industry consumes over 200 billion m3 of hydrogen per year, or over 50 per cent of all hydrogen currently produced in the world [1]. Currently, global hydrogen production is 48% from natural gas, 30% from oil, and 18% from coal; water electrolysis accounts for only 4% [2]. Hydrogen from natural gas is most favored because it is by far the cheapest method [3]. However, the first three methods of
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Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

producing hydrogen are unsustainable because the resources are finite and the waste cannot be absorbed by nature [4]. More sustainable methods of producing hydrogen have always been the concern of developed economies and industries around the world. One of such is electrolysis of water. Electrolysis require a tremendous amount of energy (700-1,000 deg. Celsius) for a hydrogen-oxygen split. To be renewable and safe, technologies have looked at solar, wind, nuclear, and geothermal sources for such energy. This high energy required for the synthesis of hydrogen from water deters many from considering or investing into this source of the useful and safe, carbon-free energy carrier. The author of this paper understands that Notore Chemicals Ltd currently procures its hydrogen for use in ammonia synthesis from leading gas companies in Nigeria, which gas companies, for cost and ease considerations, produce hydrogen predominantly via steam reformation of natural gas and partial oxidation of heavy hydrocarbons. With the requisite parameters provided, this paper will compare the cost of these methods, and the long-term savings on internal production of the hydrogen gas than procurement from external sources. employ either or both of gas reformation and partial oxidation of heavy hydrocarbon (or other methods) to produce hydrogen. As has been established above, renewability of source, environmental damage, and long-term sustainability are three major reasons why CPV is preferred over gas reformation, nuclear electrolysis, and partial oxidation of hydrocarbons heavier than naphtha. While production of hydrogen from renewable sources are more expensive currently (about 3 times more for CPV in comparison with gas
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2. Grounds for Comparison Five principle methods of producing hydrogen are gas reformation, wind electrolysis, nuclear electrolysis, PV plate electrolysis, and CPV electrolysis [5]. This paper will compare the cost of procurement of hydrogen yielding from gas reformation and that of internal production by CPV electrolysis. The author may need to visit a named gas company or two to verify its claim that they

Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

reformation), the environmental benefits, sustainability, and clean future forestallment outweigh the cost [5]. Furthermore, as governments adopt an electron economy and materials for solar power generation are mass produced, cost of energy for hydrogen production will drop significantly. Notore Chemicals will already have been positioned to be the most self-sufficient, environmentally friendly chemical industry in Nigeria, and possibly Africa, if the study anticipated to be proposed is installed. 3. Requirements for Thesis It is the wish of the author that our country as a whole consider hydrogen as an energy carrier, even as Iceland has and is developing fast and vast [6], not for an entirely hydrogen economy as some may advocate for advanced developed countries, which a study by Bossel [4] succinctly shows to make no feasible sense, but for an electron economy which looks at generating electrons (electricity) from every form of alternative renewable source. From inception in 1958 of its national fertilizer industry, Iceland has relied on hydro-generated electricity electrolysis to produce liquid hydrogen. The fertilizer plant uses 13 MW of power annually to produce 2,000 tons of

liquid hydrogen, which is then used to make ammonia for the fertilizer industry [6]. Nonetheless, this study aims to look at production of hydrogen from both concentrator photovoltaic (for infrared heat) and solid-oxide electrolizer (for electricity) as one unit incorporated into the design of the HaberBosch ammonia synthesis process, not primarily as an energy carrier, but as a raw material, wherein the surplus energy from such production may suffice the companys current electricity demands. In which case, the company gains a two-fold benefit that gives a justifiable return on investment. This would place Notore Chemicals Ltd several levels ahead of its competitors in terms of goodwill, quality of service, technological growth usage, and efficiency of production in the commodities or homogeneous products industry. Whether such a study as this to be presented is feasible or not in practice will depend on key parameters upon which the entire efficient production pathway of the company depends. Nevertheless, a theoretical ideal system may also be appropriately considered even as chemical industries in developed countries are moving toward a full hydrogen system. Of course, the author has not taken
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Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

his eyes off the abundant renewable supply of free water from the Atlantic upon which Notore is placed. The following parameters will help the author compare these costs so as to present a case that justifies a new system as to be proposed or keeps the status quo: 1. Notores current power demands (in megawatts) both for plant operation and local utility (offices and other) demands 2. Annual cost (in US dollars) incurred by company to generate and maintain such power supply efficiently and productively 3. Projected power demands for the next 10 years and source expected to generate such power 4. Typical total power requirement (megawatts) for the ammonia synthesis plant considered in isolation 5. How much acreage (in cubic meters) of land space is yet available to Notore or that can be acquired for expansion and citing of additional plants for optimum production 6. How many metric tons of ammonia are Notores annual required production target to suffice and outdo local and export demands

7. How much does it cost the company to store surplus production and via what methods 8. Does Notore currently practice Carbon Capture and Storage (CCS) or Carbon Sequestration; and how much (in US dollars), if it does, does it cost the company annually 9. Does Notore use or intend to use absorbed CO2 for its urea production 10. From which source does Notore currently procure hydrogen 11. For the required ammonia production target, how much (in metric tons or kg) of hydrogen does Notore require annually 12. How much (in US dollars) does it cost the company to procure hydrogen from these external sources 13. Did Notore ever consider internal production of hydrogen and compare such cost with that of the current system of sourcing 14. How does Notore store surplus hydrogen and how much does that cost the company 15. How much does Notore expend on safety installments for the hydrogen gas 16. Of course, what process generates hydrogen generates also pure oxygen, has Notore

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Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

considered how it could benefit from such high tonnage of oxygen 17. Any other information that may add value to this analysis; and such as may be needed from time to time as the study proceeds Such parameters as outlined above are required for a technical study that will consist of literature, design, and scaled drawings (flow diagrams) to exact details as may be required for implementation. Such details as equipment cost per kilowatts of electricity, equipment including the components of the CPV/SOEC, installation, piping, instrumentation, building and structures, etc shall be duly estimated and justified. 4. Authors Note and Non-Disclosure Term The author of this work had been long impressed with the installment of a chemical industry in his state whose line of work is majorly agro-allied. He had watched its progress carefully and thought of how to channel in some of his ideas. A buff of sustainable energy systems and principle researcher at Wafer Co RG, a company he helped form, the author stumbled on the idea to develop an integrative system of solar hydrogen generation

using concentrator photovoltaic and high temperature electrolysis into the base plant reactors for ammonia production while studying the work of Jamal R. Thompson, Robert D. McConnell, and Mohsen Mosleh (referenced). A chemical engineer from the Rivers State University of Science and Technology, the author has undertaken researches into various methods of hydrogen production that are notably sustainable, waste management (municipal and industrial), solar power generation, and fuel cell (non-combustion) engine for automobiles, etc. The author has invested a sizable sum of money into researching and studying the workability and economic reality of such a system as he has proposed to study and design, and understands that more costs would be incurred for further research and study, experimentation, tests, collaborations, information gathering, transportation, printing and production. Fully aware that Notore Chemicals is interested in research and development and open to new ideas that may expand the companys objectives and drive profitability, the author may ask that such a study as is proposed be incorporated into such a department within the company so that its cost is appropriately managed.
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Benakole: CPV/SOEC Hydrogen as Stage-I Reactor in the Haber-Bosch Process

The design to separate the solar infrared radiation incident on highly reflective parabolic concentrator solar panel and using it as the heat source for a solid oxide electrolyzer cell while the rest of the solar spectrum is converted to electricity by the photovoltaic cell and fed to the same electrolysis unit was patented by Solar Systems P/L, Australia [5]. This work is indeed a practical evolution of such a system, incorporating such hydrogen production into an ammonia synthesis plant and extending the electricity generation beyond electrolysis to domestic usage. This idea and whatever information may be included in the study is therefore privileged and ought to be protected by patent. The author also pledges to protect whatever information Notore may supply that is privileged. Rights to this study are kept by Wafer Co RG, and may be transferred fully (100%) to Notore Chemicals Ltd by agreements if the work is commissioned, funded, and possibly implemented. All rights may go with credits.

6. References: 1. T. N. Veziroglu & F. Barbir, Hydrogen Energy Technologies, Emerging Technology Series, United Nations Industrial Development Organization, Vienna, 1998 2. Hydrogen Economy, en.m.wikipedia.org/wiki/Hydrogen_economy 3. California Hydrogen Highway Network, (CaH2Net), Hydrogen Production Methods and Environmental Impacts Fact Sheet, www.HydrogenHighway.ca.gov 4. Ulf Bossel, Does a Hydrogen Economy Make Sense? Proceedings of the IEEE, Vol. 94, No. 10, October 2006 5. Jamal R. Thompson, et al, Cost Analysis of a Concentrator Photovoltaic Hydrogen Production System, International Conference on Solar Concentrators for the Generation of Electricity or Hydrogen, 1-5 May 2005, Scottsdale, Arizona 6. The Hydrogen Experiment, The Worldwatch Institute, www.worldwatch.org/node/493, 2011

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